Copolymer of modified unsaturated alkyd resin and polyallyl ester



Patented June 22, 1948 COPOLYIHER OF MODIFIED UNSATURATED ALKYD RESIN AND POLYALLYL ESTER Edward L. Kropa, Old Greenwich, Conn, assignor to American Cyanamid Company, New York, N. Y., a corporation of Maine No Drawing.

This invention relates to resinous compositions and processes of producingsuch compositions by polymerizing or reacting a reactive resin 01' the alkyd type with reactive organic substances, generally solvents, to form substantially infusible, substantially insoluble resins.

One of the objects of this invention is to preare improved resins and especially to obtain clear and colorless gels. I

It is also an object of this invention to provide potentially polymerizable solutions which would be stable during storage.

Still another object of this inventionis to control the rate of polymerization of the reactive mixture, aswell as to improve the properties and characteristics oi resulting gels.

Another object of this invention is to prepare compounds particularly suitable for use as costing compositions and as components in coating compositions.

A further object of the present invention is to prepare molding compositions and especially to prepare clear and colorless molded materials. Another object of this invention is to prepare laminated moldings having high strength and other desirable properties.

A still further object of this invention is to provide molding compositions suitable for injection molding. Other objects will be apparent from the description.

and an organic substance which contains the polymerizably reactive group CH2=CH-CH2-. The high boiling allyl compounds are the preferred reactive organic substances. Such mixtures may be utilized in coating compositions, in molding compositions, in laminating, in adhesives, in casting compositions, etc.

For the sake of brevity the organic substances which contain the polymerizably reactive group, CH2=C will be referred to herein as reactive materials or as reactive-materials containing the CH2=C group and they are thus to be distinguished from the resins which possess a plurality of polymerizably reactive alpha, beta enal groups which are designated herein as reactive resins and as unsaturated alkyd resins.

Many of the reactive materials containing the CH2=C group are solvents and therefore the reactive resins may be dissolved therein to form liquid compositions which may be used as such without the addition of any other solvent unless particularly desirable, It is to be understood, however, that I am not restricted to liquid substances which actually reactive groupings present in these acids.

Application February 10, 1944, Serial No. 521,822

14 Claims. (Cl. 26045.4)

act as solvents, since in some cases the organic liquid substances may in fact act as a solute rather than as a solvent, it being dissolved by the resin, or a colloidal solution may be produced instead of a true solution. Furthermore, the reactive material may be a resin containing a plurality of CH2=C groups or CH2=CHCH2-- groups. Such a substance could be cured by a reactive resin or by a reactive substance which contains polymerizably reactive alpha, beta enal groups. Such substances may be derived from alpha, beta unsaturated organic acids, for example, by esteriflcation of such acids. Among the reactive resins used in the practice of this invention for interaction with the reactive material containing the CHz=C groups are those which are derived from alpha, beta unsaturated organic acids and, therefore, contain Ellie e term "acids as used herein is intended to include the anhydrides as well as the acid themselves since the former may be used instead of the acid. The term alpha, beta-unsaturated organic acid as used in the art does not include acids wherein the unsaturated group is part of an aromaticacting radical, as for example, phthalic acid, and the same definition is adopted herein. 7

The resins are preferably produced by the esterification of an alpha, beta-unsaturated polycarboxylic acid with a polyhydric alcohol and particularly a glycol. Although esterification of the acid with a polyhydric alcohol is perhaps one of the simplest, most convenient ways of obtaining a reactive resin, I am not precluded from using resins otherwise derived from alpha, betaunsaturated organic acids. Reactive resins suitable for my invention are any of those containing a plurality of polymerizably reactive alpha, beta enal groups.

PREPARATION OF rm: POLYMERIZABLE MIXTURES A reactive resin such as those prepared by the esterification of alpha, beta-unsaturated organic acids and a glycol or other polyhvdric alcohol as illustrated above is mixed with the reactive material containing the group CH2=C Upon adding a. polymerization catalyst and subjecting the mixture to polymerization conditions such as, for example, heat, light or a combination of both, a substantially insoluble, substantially infusible resinis obtained,

All of the reactive substances suitable for use according to my invention for reaction with a reactive resin are characterized by the presence of the reactive group CH2.=C and none of them contain conjugated carbon-to-carbon double bonds. Compounds containing a conjugated system of carbon-to-carbon double bonds are known to react with themselves or with other unsaturated compounds such as the 'maleic esters, by a 1,2-l,4 addition mechanism such as that which has become generally known as the Diels-Alder reaction. On the other hand, compounds such as those used according to the present invention and which contain no conjugated carbon-tocarbon double bonds obviously cannot undergo this type of reaction with themaleic esters. Accordingly, my invention is not directed to the use of unsaturated compounds containing conjugated systems of carbon-to-carbon double bonds. Many substances which contain a carbon-to-carbon double bond conjugated with respect to oxygen are suitable for use according to my invention since they do not react with unsaturated alkyd resins in an undesirable manner, but, instead, copolymerize or interpolymerizc to form substantially infusible, substantially insoluble resins.

The reactive allyl compounds which may be used are any of those compounds which contain the CHz=CH-CH: group and which do not have a boiling point below about 60 0. f the allyl compounds which may be used the allyl esters form a large class all of which are suitable. The reactive allyl compounds which have been found to be most suitable are those having a high boiling point such as the diallyl esters, e. g.. diallyl maleate, diallyl fumerate, diallyl ph'thalate and diallyl succinate. Other allyl compounds may also be used which are not necessarily high boiling. As pointed out in my copending application. Serial No. 487,034, filed May 14, 1943, substantially insoluble and substantially infusible resins may be prepared by reacting or polymerizing any of the following with a olymerizably reactive resin of the type described herein, 1. "e., unsaturated alkyd resins containing a plurality of al h beta coal-groups: allyl alcohol, methallyl alcohol, allyl acetate, allyl lactate, the allyl ester of alpha-hydroxyi'sobutyric 'ac'id, allyl acrylate, allyl methacrylate, diallyl carbonate, diallyl malonate, diallyl oxalate, diallyl succinate, diallyl gluconate, diallyl methylgluconate, diallyl adipate, the diallyl ester of azelaic acid, diallyl sebacate, diallyl tartronate, diallyl .tartrate, diallyl silicone, diallyl silicate, 'diallyl'fumarate, diallyl maleate, diallyl mesaconate, diallyl citraconate, diallyl glutaconate, the diallyl ester of muconic acid, diallyl itaconate.- diallyl phthalate, the diallyl ester of endomethylene tetrahydrophthalic anhydride, triallyl tricarballylate, triallyl aconitate, triallyl citrate, triallyl phosphate, trimethallyl phosphate, the diallyl ester of ethylene glycol dicar bonate om=cn-om-o-o-o 4 cm) 0- /47H| A om=on-'om-o- -o I the diallyl ester of ethylene glycol dimalonate, the diallyl ester of ethylene glycol'dioxalate, the diallyl ester of diethylene glycol dicarbonate, the diallyl ester of diethylene glycol dimalonate, the diallyl ester of diethylene glycol dioxalate, the diallyl ester of carbonic acid or of other dicarboxylic acid, diesters of other glycols, e. g., propylene glycol, the butylene glycols, triethylene glycol, etc., tetraallyl silicate and other tetraallyl esters.

Tetraallyl compounds are not easily prepared by direct esteriflcation. One way for preparing such compounds is by the use of the acid chlorides.

Other allyl compounds which may be used for reaction with a polymerizable and unsaturated alkyd resin include reaction products of allyl malonate' with formaldehyde or glyoxal. such compounds having the following formula respectively:

Another compound which may be employed is the tetraallyl ester obtained by the reaction of allyl malonate with chloroform in the presence of sodium allylate and which has the following formula:

CHFCH-CHr-OOC ooocn=-on=cm on-on=o Still another compound which may be employed is the compound having the following formula:

and it may be prepared by reacting allyl acetylene dicarboxylate with allyl malonate.

h The polymerization catalysts include the organic superoxides. aldehydric and acidic peroxides. Among the preferred catalysts there are: the acidic peroxides, e. g., benzoyl peroxide,

- phthalic peroxide, succinic peroxide and benzoyl acetic peroxide; fatty oil acid peroxides, e. g., coconut oil acid peroxides, lauric peroxide, stearic peroxide and aleic peroxide; alcohol peroxides, e. g., tertiary butyl hydroperoxide usually called tertiary butyl peroxide and terpene oxides, e. g., ascaridole. Still other polymerization catalysts might be used in some instances such as soluble cobalt salts (particularly the linoleate and naphthenate) p-toluene sulfonic acid, aluminum chloride, stannic chloride and boron tritluoride.

The term polymerization catalyst as used in this specification is not intended to cover oxygen contained in the resin as an impurity. While this small amount of oxygen would only catalyze the reaction to a very small extent, in order to eliminate any ambiguity the term polymerization catalyst is specifically defined as excluding any oxygen present as an impurity in the resin itself.

The concentration of catalyst employed is usually small, 1. e., for the preferred catalysts, from about 1 part catalyst per thousand parts of the reactive mixture to about 2 parts per hundred parts of the reactive mixture. If an inhibitor be present. up to 5% or even more of catalyst may be necessary according to the concentration of inhibitor. Where illlers are used which contain high concentrations of substances which act as inhibitors, e. g., wood flour, the concentration of catalyst necessary to effect polymerization may be well above 5% The polymerization conditions referred to are heat, light, or a combination of both. Ultraviolet light is more effective than ordinary light. The temperature of conversion depends somewhat on the boiling point of the reactive material and also on the pressures used. At atmospheric pressure.

' as in coating and casting operation, temperatures ten degrees ((2.) rise in temperature for this reaction. A temperature is selected which will give a suitable reaction rate and yet not cause sub-' stantial volatilization. The following table shows the approximate polymerization temperatures most suitable for the named reactive materials:

Reactive Material TemperatlmiR-ange gfiggg diallyl maleate Room temp. to about 110 C- 150 to 90 C. diailyl phthalate Boom temp. to about 150 C. 60 to 90 0.

Obviously it will be necessary to use lower temperatures if large or very thick pieces are being cast because of the exothermic reaction and poor heat conductivity of the reacting mixture.

Where suitable precautions are taken to prevent evaporation of our reactive material or where pressure molding is used higher temperatures than those mentioned above could be used. Since the time of curing is desirably much shorter (in pressure molding at elevated temperatures) and since the reactive material containing the CH:=C group would not be lost so easily, a higher temperature is preferred.

The particular reactive resin, reactive material and catalyst is selected according to the type of productdesired, taking into account the solo-- bilities of the reactants as well as the character o! the resulting gels. Some combinations of reactive resins and reactive materials result in opaque gels while others give clear products in the gel state. Obviously for many purposes the opaque gel may be used equally as well as the clear gel. The following examples (the proportions being given in parts by weight) illustrate these principles and indicate optimum control conditions, particularly in comparison with less suitable con-- trol conditions:

Example 1 Diethyiene glycol maleate resin and diallyl maleate were mixed in various concentrations and treated with 0.4% of bennoyl peroxide. The following results were obtained after curing four days at 58 C.

Similar results are obtained substituting diallyl iumarate and dialiyl phthalate.

Example 2 Ethylene glycol maleate resin (acid number 50) and diallyl phthalate were mixed in various concentrations and treated with 0.4% benzoyl peroxide. The mixtures were heated at 44 C. for

. 6 twenty-four hours and then at 100 C. for three hours with the following results:

Plitbalate 24 hours 27 hours Liquid. Slightly opaque gel.

Do. Clear gel.

Example 3 Similar results were obtained with diethylene glycol maleate resin (acid number 32) and ethylene glycol maleate resin (acid number reacted with other diallyl esters:

Results after 24 hours at 0.

Parts or Soivent Parts oi Solvent Resin Resin Clear gel.

Clemgelblue.

Diallyl succinat e" Ethylene glycol maieate.

0. Clear gel- Do. Do.

.....do Diallyl succinate ...--do

Diallyl sebacate was found not to be appreciably soluble in ethylene glycol or diethylene glycol maleate resins but was soluble in long-chain glycol resins such as, for example, decamethylene glycol maleate resin.

Example 4 Ethylene glycol maleate resin (13 parts) was mixed with methallyl alcohol (7 parts) and 0.2% benzoyl peroxide. At C. the mass gelled in eight to ten minutes.

Example 5 To a mixture of about 40 parts of diallyl phthalate and about 60 parts of ethylene glycol maleate resin (acid number 18), about 0.2% benzoylperoxide was added. This was cast and cured in an oven at C. A clear solid resin was obtained in four to five minutes.

Example 6 Approximately 250 parts of diallyl maleate were heated in a bath. The temperatures of the bath as well as the solution were recorded.

Tembpielrature Temperature Bath, C.

solved in 1 part of ethyl fumarate and treated with 0.2% oi benzoyl peroxide. In approximately 7 ten minutes at 90 C. a cloudy hard resin results.

The resinous diallyl maleate was mixed with equal parts of ethylene glycol maleate and treated with 0.5% of benzoyl peroxide. At 50 C. curing resulted in a hard clear resinous mass.

Other resinous substances containing a plurality of unsaturated groups such as allyl cellulose, methallyl cellulose, crotyl cellulose, etc. could be treated in a similar manner with reactive materials or with reactive resins.

Example 7 500 parts of phthalic anhydride, 103 parts of ethylene glycol, 225 parts of allyl alcohol, 225 parts of toluene and 3.4 parts of p-toluene sulfonic acid were heated in such a manner that the hot vapors passed through a bubble-cap fractionating column before condensing. The water was separated and the other components returned to the still. The heatin was continued for ap proximately 16 hours. The mass was then heated in a low vacuum to remove the low boiling constituents and then in a higher vacuum (4 mm.) The bath around the flash was maintained at approximately 180 C. for 2.5 hours to remove volatile materials.

The residue remaining was a soft fluid viscous resin of acid number of 38.

One part of the above resin was mixed hot with 1 part of alpha propylene glycol maleate resin and treated with 0.2 part of benzoyl peroxide at 120 C. rapid curing was obtained.

Example 8 Equal parts of diethylene glycol maleate resin (acid number 32) and diallyl maleate were mixed with 0.02% co balt naphthenate and 0.2% benzoyl peroxide. At 100 C. films of this composition on glass dried to very hard brittle coatings in ten minutes. One hour at 90 C. was required to obtain similar coatings when diallyl succinate was substituted for the diallyl maleate.

Example 9 Thiethylene Result at 90 C. at-

Ethylene Glycol Malcate Diallyl M aleate 11 min. 20 min.

Parts Parts Example 10 Compositions similar to those of Example 9 were made using the same proportions of diallyl maleate resin and catalyst. The following results at 90 C. were obtained with the resins indicated, the proportions being given in mol Resin Drying time 50% Tnethylene glycol, 12.5% Fumaric, 37.5% Minutes Phthahc 12 50% 'Ir ethylene glycol. 25% Fumaric, 25% Phthalic i2 507 Tnethylene glycol, 40% Fumaric. 16% Phthalic. 12 50 a 'Inethylene glycol, 25% Fumsric, 25% Pineneiumaric Made by reacting mol oi pinene to 1 mol oi iumanc) 20 The resin with tumaric acid is not so flexible as with 50 iumaric acid. Example 11 60 parts of diallyl maleate were mixed with 40 parts oi. diethylene glycol phthalic-maleic resin (50% phthalic-50% maleic). Films of this mixture dried from the bottom but the top remained soft. The addition of linseed fatty acids to the resin, however, eliminated this tack.

For coating compositions too large a proportion of maleic acid in the resin should not be used if best adhesion and pliability is desired. To eliminate the slight amount of surface tack, the alkyd resin may be modified with a small amount of drying oil acids. Drying oils containing a number of unsaturated linkages should be used. The alkyd resin should preferably contain a certain number of oxygen bridges to get good surface drying.

Example 12 Phthalic anhydride parts) triethylene glycol parts) and linseed oil (15 parts) were heated in an atmosphere oi COz'at 180 C. for eight hours, resulting in an acid number of 81.8. To the cooled mix there was added maleic anhydride (98 parts) and ethylene glycol (70 parts) and the mixture was then heated eight hours at C. under C02. During the last fifteen minutes the gas was blown through quite vigorously to remove the volatile ingredients. After further heating at 150 C. for five hours a resin of acid number 20.3 was obtained.

This resin was dissolved in, diallyl maleate in the ratio 60:40, respectively and 0.2% benzoyl peroxide and 0.05% cobalt drier were added. Films of this dried on tin at 90 C. in fifteen to twenty minutes. They were hard and resistant.

Example 13 46 parts of glycerol, 49 parts of maleic anhydride, 35 parts of linseed oil acids and 69 parts of undecylenic acid were heated to C. during about three hours. Compatibility did not occur and the mass gelled. Upon the slow addition of the linseed oil acids to the hot mixture of the other ingredients compatibility was established.

The resin (12 parts) resulting from this reaction was dissolved separately in diallyl maleate (8 parts) and also in toluene (8 parts) and treated with 0.5% benzoyl peroxide and 0.05% cobalt naphthenate and baked at v90 C. The resindiallyl maleate mixture dried in less than an hour whereas the resin-toluene mixture required one and one half hours to dry.

Obviously, the mixture containing the reactive resin and reactive material containing the CH2=C group can be mixed with lacquer ingredients and solvents such as cellulose derivatives. The following example illustrates such a coating composition:

Example 14 Percent Nitrocellulose 29.2 Ethanol 12.5 Ethyl acetate 58,3

Benzoyl per minutes at 90 C. to yield a clear, glossy, hard The following examples show molding compositions and shaped or molded articles comprising my polymerizable reactive mixtures:

Example 15 To 125 parts of cellulose filler (Novacel) about 22 parts of diallyl phthalate containing about 0.1-0.2 part of benzyl peroxide are added and the resulting composition is placed in a suitable mixer, e. g.,-a Banbury mixer, and agitated until homogenized. About 45 parts of the solution containing 75% of ethylene glycol maleate and 25% of diallyl phthalate are added and the entire mixture is ground for about 35 minutes.

The resulting product is molded at temperatures of about l30-150 C. and at pressures up to about 3000 pounds per square inch. Small dish-like moldings are produced at this temperature and pressure in about 3 minutes.

Example 16 Parts Ethylene glycol maleate resin 50 Diallyl phthalate 50 Benzoyl per 0.05

t-Butyl peroxide 0.4-0.5 This composition may be ground if necessary 'to disperse the benzoyl peroxide thoroughly.

into a hot mold.

Example 17 Parts Resin "E 60 Diallyl phthalate 40 Resin E is dissolved in the diallyl phthalate and the benzoyl peroxide is added. The above solution is coated ontoglass fabric" and placed between smooth platens. A pressure of about 10-15 pounds/sq. ins. is applied to the platens, in order to remove entrapped air. The assembly is then heated at about 150 C, for about 2 hours. The platens are removed and a still sheet results.

Using 2 plies of. glass cloth, possessing the trade name EC-11-161 (sold by Owens-Corning Fiberglas Corporation), the following physical properties were obtained using the above resinous composition:

Tensile strength (+25 C.)

32,000 pounds/sq. in. 27,100 pounds/sq. in.

The diiference in strength was obtained by cutting specimens parallel to and at right angles to the warp.

The modulus in bending values were:

9.6 10 pounds/sq. in. at 40 C. 6.1 pounds/sq. in. at 40 C. 9.6)(10 pounds/sq. in. at +25 C. 7.3)(105 pounds/sq. in. at +25 C.

Here again tests were conducted parallel to and at right angles to the warp,

The above liquid composition may be applied by means of a doctor blade, by dipping, followed by squeeze rolls, byspray or by brush.

Resin "E above was prepared by heating 6 mols of diethylene glycol, 5 mols of fumarlc acid and 1 mol of sebacic acid at about 200 C. until an acid number of about 50 was obtained.

Erample 18 Parts Diethylene glycol fumarate 50 Diallyl phthalate -1 50 Lauroyl peroxide 0.5

The above composition is cast between sheets of glass. A paper spacer of approximately 30 mils is used to separate the glass sheets. The resin is forced into this space by means of a hypodermic needle. The assembly is maintained for about 1 hour at 150 C. The assembly is cooled and placed in cold water. A thin, flexible, hard sheet of resin resulted. The composition is especially transparent since both sides of the sheet had taken the surface from the glass.

Such sheets of resin may be used directly or may be sealed onto other surfaces and used as a coating. When such materials are to be used as coatings, it is preferable to abrade one surface. This may be accomplished mechanically or in the manufacture thereof by the use of etched glass as one castin surface in the above assembly. I

Example 19 A thin, flexible sheet may be prepared by using a formulation such as follows in the process outlined in Example 18.

Parts Resin F 50 Diallylphthalate 50 Benzoyl peroxide 1 Resin F is prepared by heating 2 mols of sebacic acid, 1 mol fumaric acid and three mols of ethylene glycol at about 200 C.-until the acid number is about 50. v

A flexible sheet is formed which is similar to that obtained in Example 18.

Example 20 In order to produce compound curved laminated forms, the following procedure has been found satisfactory: Canvas or glass cloth cut to size is impregnated with the reactive mixture employed in Example 17. The layers of impreg- .nated resin are placed in an appropriate form and a vacuum applied, suitably with a rubber I bag. The assembly is then heated for approximately 5 hours at 100 C.

Example 21 Parts Diallyl phthalate 48 Ethylene glycol maleate resin 32 Toluene 10 Ethanol 10 Benzoyl peroxide 0.6 t-Butyl peroxide 0.4

11 stage. ;This operation requires approximately 2-3 hours. The impregnated canvas should be molded immediately or if allowed to stand for any time, precautions should be taken to avoid exposure to air or oxygen.

The sheets of impregnated canvas are out. stacked and molded under heat and pressure at about 2000-3000 pounds per square inch and at temperatures around 125 C. for approximately 4 hours, thereby producing a laminated cloth plate of very high transverse strength.

Alternatively, cut canvas sheets may be impregnated with the above composition without the use of the volatile solvents, alcohol and toluene.

The solution of diallyl phthalate and alkyd resin is applied to canvas using equal weights of canvas and reactivecomposition. The assembled sheets are placed between platens and placed ,in a press. A pressure of about 50 pounds/sq. in.

is applied and the mass cured at 150 C. for 1.5 hours. A still! cured resinous material results. Paper may be impregnated in a similar manner. For example, a composition containing approximately 45-50% resin has a transverse strength of about 16,000-l9,000 pounds/sq. in. This laminated plate is particularly suitable for use in production of gear wheels because of the high transverse strength and since it may be machined easily.

Example 22 Parts Ethylene glycol maleate resin 60 Diallyl maleate 40 Benzoyl peroxide 0.! Cobalt naphthenate 0.04

' This mixture is used to impregnate canvas and ,the impregnated canvas is heated at about 80 C. for around 30-35 minutes in an oven. The material is then cut, stacked and molded at a pressure of about 2500-3000 pounds/sq. in. at a temperature of about 125 C. and for approximately ,3 hours. The molded plate thus produced has a Example 23 Parts Resin G 50 Diallyl maleate 50 Benzoyl peroxide 'I This composition is-applied to paper on a tube rolling machine, the machine comprising suitable rollers for paper and a means for distributing a uniform coating of resin on the paper. After the resin-impregnated paper has been rolled, the roll is cut, stacked and partially cured (i. e., polymerized) at about 110 C. and then molded at somewhat higher temperature, e. g.,

120-130" C. at a pressure of about 2000 pounds/sq.

in. The resulting molded plate has good electrical properties and it has excellent transverse strength. If desired, cylindrical moldings can be produced by suitable modification of the apparatus and process.

Resin "G is prepared by heating at about 180 12 c. under an inert atmosphere 850 parts of phthalic anhydride. 420 parts of maleic anhydride. 800 parts of triethylene glycol. 410 parts of ethylene glycol and 180 parts of linseed oil fatty acids in a suitable reaction chamber provided with a reilux condenser which has a water trap to separate the water formed during the esteriilcation from the condensate. The mixture is heated for about 4-12 hours or until a relatively low acid'number is obtained. e. g.. about 20.

p Example 24 a .60 parts or diethylene glycol fumarate and about parts of triallyl phosphate are blended together and about 0.2% benxoyl peroxide is added. Castings of the resulting polymerizable composition may be rendered substantially insoluble and substantially infusible by heating at a temperature of about 80-120 C. for around 1-4 hours or more.

' Example 25 parts of diethylene glycol maleate, about 50 parts 01' triallyl phosphate and 0.2 part of benzoyl peroxide are mixed together. A small casting completely polymerizes at about 50 C.

in about 16 1101111.

Example 26 10 parts of trialiyl tricarballylate are make with 10 parts of diethylene glycol maleate resin and 0.4% benzoyl peroxide. The resulting reactive mixture is heated in the form of a small casting tor about 40-60 c. for about 24 hours andthen at about 100 C. for several hours. Ahard clear casting is obtained.

Example 27 Vrscosrrr Amos-mam or Rxsc'rrve Mrxruar:

It is sometimes desirable to reduce the viscosity of our mixtures of reactive resin and reactive material containing the CH2=C group, as for instance, when a very viscous resin is to be used for coating. It is possible to do this by adding an esteriflcatlon catalyst, e. g., p-toluene sulfonic acid and then heating until the viscodty goes down. The mechanism of this change is probably reesteriflcation. This is also useful when the composition is to be baked at high temperature, under which conditions the reactive material would be lost in part by evaporation. If this "thinning, process is carried out, the reactive material is combined with the resin by reesteriflcation and is not lost. It is also desirable to add a polymerization inhibitor before the heating or thinning" process.

Example 28 A resin made by esteriflcation at 150 C. of 294 parts of maleic anhydride, 121 parts sebacic acid, 227 parts of ethylene glycol, 32 parts of linseed fatty acids and 3.6 parts of p-toluene sulfonic acid was mixed with diallyl maleate in the ratio or parts of resin and 40 parts of diallyl male- 13 ate, 0.01% p-toluene sulfonic acid added, and the mixture heated in an oil bath at 90 C. for five hours. The viscosity decreased from to 8 poises.

In casting or molding operations using a mixture of a reactive resin and reactive material containing the CH2=' group, it may sometimes be desirable to body the reactive mixture before adding the catalyst in order to out down the induction period which would otherwise be too long. 1

This-may be done by heating a mixture of resin and reactive material from about 70 C. to about 110 0., preferably at about 90 0., for sufllcient length .of time to substantially reduce the induction period. This time will vary with each resin-reactive material combination with the initial viscosity and other such factors but may be determined by observation of the rise of viscosity. The heating should continue until the viscosity begins to rise rapidly. A general rule for determining the heating time is to heat the mixture until the viscosity is about two to three times the initial viscosity.

After the bodying operation is carried out, the polymerization catalyst is added to the mixture and the whole subjected to polymerization conditions. The use of liquid peroxides instead of solid peroxides is an advantage after bodying the resin mixture since it is difiicult to get the solid peroxides dissolved rapidly enough, Peroxides of the coconut oil acids, tertiary butyl peroxide and I ascaridole are suitable liquids.

By the use of this process the induction period is cut down from approximately /2 to $4; the time that is required when the bodying process is not used. Even greater reductions are obtained with some mixtures.

In bodying reactive mixtures containing the reactive resin and a reactive material containing the CH=C group wherein the proportion of reactive material is greater than about the viscosity rise is so sudden that it may be somewhat diflicult to control it. Accordingly, if it is desired to body a resin-reactive material mixture containing more than 30% of reactive material, an alternative procedure is used. By this method one first bodies a mixture containing only 30% of reactive material. Then a small portion of additional reactive material is added, for example, sufllcient to make the reactive material concentration 40% and then this is bodied. If still more reactive material is desired, another small portion of reactive material is added and the bodying process repeated. This process is repeated until the desired concentration and viscosity is obtained.

ADDITION or INHIBITORS One of the difficulties in the use of the compositions described above is that they are not susceptible to storage in the mixed form because polymerization will usually take place even at room temperature within a comparatively short time. Moreover, when it is desired to cure the compositions very rapidly underheat and pressure, the reaction becomes at times so vigorous that it cannot be controlled. In order to overcome these difflculties it has been found advisable to incorporate a small proportion of a polymerization inhibitor in the mixture of resin and reactive material. When it is desired to use this mixture, a small percentage of the polymerization catalyst is added, sufiicient to overcome the effect of the inhibitor as well-as to promote the polymerization. By careful control of the concentrations of inhibitor and catalyst, a uniform product is obtainable with a good reaction velocity. Upon subjection of this mixture to polymerization conditions such as heat, light or combination of both, and with or without pressure, an infusible, insoluble resin is produced which has many more desirable characteristics than the resins'produced by the polymerization of mixtures not containing the polymerization inhibitor such as. for instance, the lack of fractures.

Suitable polymerization inhibitors for this reaction are phenolic compounds especially the polyhydric phenols and aromatic amines. Specific examples of this group of inhibitors are hydroquinone, benzaldehyde, ascorbic acid, isoascorbic acid, resorcinol, tannin, sym. di, beta naphthyl p-phenylene diamine and phenolic resins. Sulfur compounds are also suitable.

The concentration of inhibitor is preferably low and I have found that less than about 1% is usually sufflcient. However, with the preferred inhibitors I prefer to use only about 0.01% to about 0.1%.

The inhibitor may be incorporated in the reactive resin-reactive material combination (either before or after bodying) or it may be added to the original reactive resin before or during the .esterfication of the said reactive resin. By adding the inhibitor before the esteriflcation it is sometimes possible 'to use an inhibitor which would otherwise be substantially insoluble in the reactive resin-reactive material composition. By

adding the inhibitor to the unesterified mixture the inhibitor may become bound into the resi upon subsequent esterification.

Example 29 Resins were made up of the following compositions by esterification for the same length of time at 0.:

Ingredients Resin No. l Resin No. 2

Maleic Auh dride 49 Ethylene G ycol 41 P "-nhyde Rsacrrvr: RESINS AND THEIR PREPARATION Reactive resins suitable for polymerization with reactive materials containing the CH2=C group in accordance with the teachings of my invention are those which contain a plurality of alpha, beta enal groups. The simplest members of this group are those produced by the esterification of an alpha, beta-unsaturated organic acid with a polyhydric alcohol.

The preferred polyhydric alcohols are those which contain only primary hydroxyl groups since the presence of secondary hydroxyl groups may make it dimcult to obtain rapid esterification. 'I'he glycols are generally preferable. If colorless resins be desired or if optimum electrical properties be desired, it is preferable to use glycols which do not have any oxygen bridges in their structure since the presence of oxygen linkages filayleadto clear colorless resins polyhydric alcohol.

the formation of coiorbodles during thepreparationoftheresin. Bytheuseof glycols which do not contain the oxygen bridges may be produced. On the other hand, oxygen bridges may be desirable if theresinistobeusedincoatingastheycause iilms to dry faster.

particular choice of glycol or other polyhyin general.

The alpha. beta unsaturated organic acids which I prefer to use in preparing the reactive resins include maieic, fumaric, ltaconic and citracmic although other similar acids could be substituted such as mesaconic acid, aconitic acid and halogenated maleic acids such as chlormaleic acid and any of the foregoing could be substituted in part with acrylic. beta bensoyl acrylic methacryilc, a -cyclohexene carboxyllc, cinnamlc, and crotonic acids. Obviously, various mixtures of these acids can be used where expedient.

The reactive resins may be modified with other substances which are used in alkyd resins, i. e., monobydric alcohols, monobasic acids or dibasic acids, s. g., phthalic acid, succlnic' acid, glutaric acid, adlpic acid, azelaic acid, sebaclc acid, 'etc., which do not contain groups polymerizably reactive with respect to organic substances containing CHr=O groups. These modifying agents are usually used as a diluents or plasticisers, chemically combined in the resin. The use of a small proportion of the saturated dibasic acids generally improves the mechanical properties of the resins after copolymerization with the material containing the CH2=C group.

The reactive resins may be prepared from polyhydric alcohols other than the glycols or from mixtures including a glycol and a higher Examples of these are glycerol, pentaerythritol, etc. Polyhydric alcohols containing more than two hydroxyl groups ,react very readily with the alpha, beta unsaturated organic acids. Consequently it may be preferable to use some monohydric alcohol in conjunction with the alcohols which contain more than two hydroxyl groups or else some monobasic acid maybe used.

It is also possible to introduce initially into the resin structure a certain number of groupings of the type CHg==C through the use of unsaturated alkyl compounds. One way of accomplishing this, for example is by direct esteriflcation of an unsaturated alcohol containing a CH:=C group. Examples of such alcohols are allyi alcohol and methaliyl alcohol.

While the reactive resins may be modified in the same general manner as other alkyd resins, it is preferable to have at least 20% polyhydric alcohol in the reactive mixture and at least polybaslc acid in said reactive mixture. If a monohydric alcohol or a dibasic acid which does not contain polymerizably active groups with respect to organic substances containing the CHz=C groups be used, the proportion of such substances will depend on the properties required of the polymerized reactive material-reactive resin mixture. By the use of a relatively large proportion of a polymerizably active dlbasic acid, e. g., malelc, in the reactive resin, a hard, tough polymer is produced upon subsequent reaction of said reactive resin with a reactive material containing the CH=C group. On the other hand, if the reactive resin is obtained from a relatively small proportion of polymerizably active dlbasic acid and a relatively large proportion of acids which do not contain groups polymerizably active with respect to organic substances containing CH2=C groups, a softer and more rubbery resin results upon polymerization with a reactive material containing the CH2=C group, The same eflect is produced by the introduction of other inactive ingredients. By varying the ingredients and the proportions of the ingredients, resins may be obtained having properties desirable for almost any particular use.

The unsaturated alkyd resins employed in accordance with my invention are preferably those having an acid mmiber not greater than 50 although in some cases resins having an acid numher as high as may be desirable. Generally the acid number should be as low as possible, but this is sometimes controlled by practical considerations of operation such as time, temperature and economy.

The resins should be so formulated that the carboxyl groups of the acids are reacted with the theoretical molal equivalent of the hydroxyl groups of the alcohols. In this connection it is to be noted that the hydroxyl groups of modifying alcohols as well as the carboxyl groups of modifying acids should be included with the hydroxyl groups and carboxyl groups of the principal reactants, the polyhydrlc alcohol and the alpha, beta unsaturated polycarboxylic acid, respectively.

If it be desirable to introduce lower alkyl groups into the resin, this may be done by using maleic esters of monohydric alcohols, e. g., ethyl maleate. The alkyl ester will then be united with the resin by polymerization. This could not-be accomplished with the saturated type of alkyd, e. g., phthalic acid esters of polyhydrlc alcohols.

Resins which contain a plurality of alpha, beta enal groups are sensitive to light, heat and polymerizing catalysts. Since oxygen tends to cause these resins to polymerize, it is desirable that the resins should be made in the absence of this substance, especially when colorless resins are required. The exclusion of oxygen and polymerizing catalysts is desirable during the preparation of the resin and the presence of dissolved oxygen in the original reactants is also preferably avoided. Moreover, dust and extraneous particles that reagents may pick up usually should be removed, especially if colorless resins are desired. One manner in which the dissolved gases and other extraneous impurities may be removed is through the distillation of the ingredients into the reaction chamber in the absence of air.

In order to lreep oxygen from contact with the reactants an inert gas such as carbon dioxide or nitrogen may be introduced into the reaction chamber. This may be done either by merely passing the gas over the surface or by bubbling the gas through the liquid reactants. In the latter instance it may be made to perform the added function of agitating the mixture thus eliminating the necessity for mechanical agitation. The inert gas will also carry away at least part of the water formed and toward the end of the reaction it can be used to carry away the reactants still remaining unreacted. Upon separation of the water vapor the used carbon dioxide or other inert gas would be particularly sultable formakinghign grade colorless resins since any real reactive impurities such as oxygen would ha e been removed in its passage through the first batch of resin reactants.

The efl'ect of light is not so important if the reactants are'puriiled and the reaction carried on in an inert atmosphere as outlined above. However, as an-added precaution the esteriilcation may be conducted in the dark. It is also advisable to avoid local overheating and discoloration is minimized if the reaction is conducted below a temperature of about 200 C. To avoid overheating it is advisable to raise the temperature slowly at the beginning, especially if an anhydrlde be used since the reaction between an anhydride and an alcohol is exothermic.

The preparation of the reactive resins is illustrated in the following examples, the reactants being given in parts by weight.

Pursue-Ion or Rnsm A 98 parts of freshly distilled maleic anhydride were reacted with about .in excess of equimolecular proportions of freshly distilled ethylene glycol (88 parts) at about 170-175 C. An excess.

of ethylene glycol is preferred because of its high volatility. The mixture is continuously agitated andcarbon dioxide is introduced into. the reaction chamber during the reaction thereby blanketing the surface of the reactants. After eight to twelve hours a clear, water-white resin is produced with an acid number of -50.

I Panrsas'rrox or Resin 3" Diethy-lene glycol (106 parts) and maleic anhydrlde (98 parts) were separately vacuum distilled into a reaction chamber which had been used in previous preparation, and the mixture was stirred mechanically while carbon dioxide gas was introduced over the surface of the resin to exclude air and to remove water that was formed in the esterlfication. The reaction was conducted at 170 C. for a period of from eight to twelve hours yielding a resin of acid number of 35-50.

Parrsasrron or Ream "C" Pause/mom or Rsscrrvl Ream, AZIOTROPICALLY Since the viscosity of the resin frequently becomes quite high if the esterification is carried to a low acid number, it may be desirable to produce the resin under azeotropic conditions. Accordingly, the esteriflcation is conducted in an organic solvent which dissolves the reactants as well as the resultant resin and which is preferably substantially insoluble in water. Examples of these are: benzene, toluene, xylene, chloroform, carbon tetrachloride, ethylene dichloride, propylene dichloride, ethylene and propylene trichlorides, butylene dichloride and trichloride and also higher boiling solvents such as cresol and methyl cyclohexanone although some of these may tend to darken the resin. The mixture is refluxed in such a manner as to separate the water formed by the esterification. .Much lower temperatures are used than are used under the 18 conditions outlined in Examples 17-19. Suitable temperatures range between 90-145" 0., for example, for the lower boiling members of the group of solvents set forth above. Obviously. this will vary with diflerent solvents and with diilerent concentrations of solvent. The range of preferred concentrations for the inert solvent is from about 25% to about An esterification catalyst is usually necessary because a comparatively low temperature is employed. Examples of these are thymol sulfonic acid, d-camphor sulfonic acid. naphthalene sulionic acid and p-toluene sulfonic acid. Obviously other known esterification catalysts could be used. A resin having any particular acid number if made azeotropically will usually have a lower viscosity than one oi the corresponding acid number not made azeotropically.

Pursasrron or Rasrn "D" 98 parts of maleic anhydride (vacuum distilled), 106 parts of diethylene glycol (vacuum distilled), about 175 about 3 parts d-camphor sulfonic acid were mixed in a reaction chamber. ducted in an oil bath maintained at 130-l45 C. for nine hours. The distillation temperature began at about 90f C. but gradually rose during the heating. The apparatus was so arranged that the water would be separated from the reflux. A light yellow resin with an acid number of about 19.8 was produced after driving of! the volatile ingredients including the ethylene dichloride.

Similar results were obtainedusing thymol sulfonlc acid and approximately the same'proportions except that only about 148 parts of ethylenedichloride were used. A 11.3 was obtained.

The resins prepared in the manner illustrated above are merely exemplary of the reactive resins which I contemplate using for reaction with a material containing the CH2=C group in the resin of acid number practice of my invention. Other resins of the same type may be prepared in a similar manner. Among these resins the following may be employed in place of part or all of those mentioned above: ethylene glycol fumarate, diethylene glycol fumarate, alpha propylene glycol maleate, polyethylene glycol maleates (e. g., hexaethylene glycol maleate), polymethylene glycol maleates (e. g.. decamethylene glycol maleate), octadecan diol fumarate, the maleic esters:

propanediol-1,3, of 1,3-butanediol, of 1,2-propanediol and of 2-ethyl, 2-butyl butanediol-1,3,

glycerol maleate undecylenate, triethylene glycol chlormaleate, triethylene glycol terpene maleate (derived from the interaction of V2 mol of terpene and 1 mol of maleic in the presence of excess of terpene).

Many different modified alkyd resins may be employed in the same manner as the other resins mentioned herein. Such modified resins include all of those previously mentioned and generically described modified with a monohydric alcohol or with a monocarboxylic acid or with both a monohydric-alcohol and a monocarboxylic acid. be used are the amylalcohols, cyclohexanol. n-hexanol, 2-methyl hexanol, n-octanol, decanol, dodecanol, tetradecanol, cetyl alcohol, octadecanol, benzyl alcohol, phenylethy alcohol, furfuryl alcohol, tetrahydrofurfuryl alcohol and various .ether alcohols sold under the trade names of Cellosolve" and the Carbltols" such as butyl Cellosolve (the monobutyl ether of ethylene glycol), butyl Carbitol (the monobutyl ether 01' parts ethylene dichloride and- The heating was-conof 2,2-dimethyl diethyiene glycol), etc. Furthermore. various chemically unchanged. In the present invention monohydric alcohols may be reacted with glycidol however, the combination of the reactive mateand the reaction products thereof employed as rial containing the CH2=C group which acts as a glycol in the preparation the unsaturated the solvent and reactive resin becomes an inalkyd resins. Still other alcohols which may be 5 separabieentity. the original ingredients not beemployed are terpineol. tenchyl alcohol, the uning removed by the solvents for the original insaturated alcohols, including aliyl alcohol. methgredienta, allyl alcohol, oleyl alcohol, linoleyl alcohol. 1 Through the use of a small amount '0! reactive have found that copolymers oi alkyd resins modialkyd resin dissolved in a large amount of reaciied with monohydric alcohol gives especially 1o tive material containing the CHr=C group, the high temperature resistance when employed as a ilnal composition contains not only the ester bond to laminate glass cloth or when glass fibers groupings which were originally present in the are used as a filter in castings or moldings. alkyd resin but also the carbon-to-carbon molec- Monocarboxylic acids which are saturated may ular bonds which link the reactive material and be employed as modiilers tor the unsaturated the reactive resin. Through the use of a small monocarboxylic acids heretofore mentioned. amount of resin and a large amount of reactive Such acids include: acetic acid, caproic acid. material, the composite resin is no longer solulauric acid, stearic acid. etc. Any of the monoble in those inert solvents 'wherein the reactive carboxylic acidswhich are available in the form material resinified alone would dissolve. Under oi the anhydride may be used as the anhydride long exposure to the inert solvent but it does not instead of as the acid. I possess the solubility of the reactive material When a resin is treated with a reactive matewhen resinifled alone. This property is a distinct rial con ini the CH =C group. the material advantage in that the physical contour of an 1 may may not dissolve the resin depen 0!! object made of the polymerized resin is not lost the chemical nature of both the material and through solution.-

the resin. It the resin be incompatible with thi Comparison of the softening point of the rereactive mat r hc em calinte acticn o t im active material containing the cm=c group described cannot occur in that compatibility has alone and or the soitening point of the composite not been establlshed- Unde conditions resin formed through interaction or the resin other solvent may t e e uced as a d and reactive material shows that the softening tional constituent. I! the solvent is inert, it plays point of the latter has been raised. The softenno part in the reaction but is so selected that m pojnt, may be increased very markedly both the reactive material and the resin are solupending upon t ratio of resin q in the ble yielding a homogenous system oi reactive maposition terial, inert solvent and resin. This invention re- In general the gte m point of "Sing 1 I -WW compatible munitions of reactive distinct bearing on their behavior at room temin and a reactive material containing the CI-Ia=C p t as well s t elevated temperatures.

- group. Such combinations may be obtained by where the ft i point is too low, mu

the use oi inert blending solvents where neces- 3mm!!! the materials to in slowly lose their shape. In large articles the containing the cm=c group wmch act elIect becomes very noticeable. A softening point vents is preierred. h n too high, on the other hand, results in a Tnemwmmtmle and homogemus as used composition which will not soften suillciently in in the specification and 01511118 are intended to a mold. th types of compositions indicate system the nautuents of which are exist with respect to the ratio oi! resin to reactx gg lg gag g gx g g mx fi tive material containing the CH==C group. these may be either true soldtmns or c0110 an First, a large amount of reactive material and a solutions as long as they are substantially stable. i22 zg x g lff m i 21:; when a reactive resin and a reactive material um f resin nd a amount reactive containing the CH==C group undergo chemiamo o cal reaction, certain possibilities arise. The rematerial The second composition when active resin and reactive material may combine cured possesses no softening in such a manner as to lead to the formation of and third varieties of comp on w an cure a resinous colloidal entity and the end-product temperatures and pressure be is clear, glass-like and homogeneous. Altemaat m slightly b d I bst tm tively, the reactive resin and the reactive matee 0 8 gm 52 rial may interact in such a manner as to yield quantifies mc ve ma con colloidal entities wherein varying degrees of the and "active m the opacity or colloidal colors result. The end-prodcured state may be macmmd' turned act under these conditions maybepanmly tram w sanded and polished and used in general. as a ment or 098mm turnery composition. The absence 0! soitenins The final resin composition is obtained by u renders the material particularly adaptable to solving a resin ontaini th fllpha be u this purpose. ,In that it is unilowable, it may be machined without danger of softening and gumi; Q 65 ming tools. Moreover, such a composition may,

r D if desired, be obtained in large blocks. groups in a reactive mat rial containing t My resins may be utilized in: moldings, with group c==cm. Th h i l r a ti which 1 or without filler; laminated materials as the bondbelieved to take place is that the reactive mates nt; adhesives; h! mp t o f r rial combines with the resin at the points oi un- 10 u i finishes fo wood. metals or plastics. or saturation yielding a less unsaturated system in the treatment of fibrous materials suchas which is essentially insoluble and intusibie. Ordipaper, cloth or leather; as impregnating agents narily when a resin is dissolved in a solvent, the for" fibrous materials; as assistants in dyeing. changes which occur are physical in nature. The etc.

resin may be isolated from the solvent mixture In order to use the composition for moldinls,

is encountered in that articles made trom the resto prevent the composition from curing too fast. uring the change from a liquid to a hard resin, varying stages of hardness exist and by interrupting the reaction at a deilnite point, the material may then be placed in a form and hardened under heat. Sheets of resin may be twisted, or made to conform to a pattern, and then subsequently cured in the shaped form 'by heat alone.

One manner in which this may be accomplished is to polymerize the reactive resin and reactive material containing the CH2=C group without catalysts until the material is no longer fluid but still not completely cured. By grinding this partially polymerized material a molding composition is obtained which can then be shaped under heat and pressur Example 28 A mixture of about parts by weight of dlallyl phthalate and about 60 parts by weight of ethylene glycol maleate resin (acid number 18) was mixed with 0.2% benzoyl peroxide. This would ordinarily gel in five to six minutes at 90 C. The mixture was prewarmed for two minutes'at 90 C. and poured into the mold, the pressure raised to 2000 pounds for about two minutes and then lowered to 1000 pounds. The mold was opened after eight minutes to yield a clear hard disk.

Example 29 it may be necessary A mixture of equal parts by weight of butylene glycol fumarate, (prepared by heating molar quantities of butylene glycol and fumaric acid at about 175 C. until the resin has an acid number of about 0.5% of benzoyl peroxide and poured into a mold.

the sides of which are two sheets of plate glass spaced $4; inch apart. The assembly is heated for about hour at 100 C; Under these conditions. a flexible sheet is formed.

The sheet may be distorted and bent into various forms. By further curing in the bent form the resin hardens and assumes the form imposed.

One procedure is as follows: A mandrel was lightly covered with glycerol, the flexible sheet is bent over the mandrel and the resin is covered with glycerol. A thin sheet of metal is then superimposed on the assembly and secured mechanically. The entire mass is heated in an oven for 1'- hour at 150 C. A hardened shaped mass results.

The glycerol is used to maintain the original clear surface. It is particularly useful where one surface is glass since the cured resin may adhere very tenaciously to glass.

All types of simple curves can readily be fashioned. Compound curves are more diflicult to produce since the resin in the semi-cured stage may be distensible to only a limited extent.

To produce moldings or laminated materials combinations of reactive resin and reactive material containing the CH2=C group may be mixed with one or more of the various fillers, e. g., wood flour, wood fiber, paper dust, clay, diatomaceous earths, zein, glass wool, mica, granite dust, silk flock, cotton flock, steel wool, silicon carbide, 'p'apen-cloth of any fiber including glass, sand, silica flour, white, black or colored pigments, etc. Such mixtures may be partially polymerized, ground and molded. On the other hand, the liquid composition may be bodied and introduced directly into a mold and polymerization from a viscous liquid to a solid resin conducted in one step.

and diallyl phthalate is treated with wherein thematerial lotion of these] into a various stages occur In that the composition of reactive resin and reactive material is initially quite limpid. it may be used for impregnating various porous objects or employed as a coating composition.

If the polymerizable compositions are to be molded under low pressure (e. g. 0-50 pounds/sq. in.) the composition may be employed without bodying or partial polymerization.

The liquid polymerizable mixture may be intro- 7 duced in aapositive mold without any filler. In this instance, however .the reaction becomes quite exothermic but this may be conveniently controlled by the addition of a suitable polymerization inhibitor.

The ratio of reactive material containing the CH2=C group to reactive resin in the final composition will not only have a bearing on the sofcombine are various. Heat, light or catalysts may be used or combinations of these, or a combination of heat and pressure. Any suitable method of heating may be used including the application of-high frequency electric fields to in-' duce heat in the reactive mixture the latter.

During'the transformation of the soft, limpid resinous-composition to to polymerize which may be roughly sopfirst, the induction period remains as a sol which slowly increases in viscosity; secondly, the transformagel; and third, the hardening of the gel. During the transformation of the sol to a gel. an exothermic reaction occurs which may be very violent if uncontrolled. Moreover, the gel has relatively poor heat conductivity re sulting in heat being transferred poorly through the mass, not only external heat but the heat that is generated during chemical reaction. Cognizance has to be taken of these features in the hardening of the composition, particularly in the casting or molding of large blocks.

Light when used alone causes arated as follows:

. induction period and during the transformation of the sol to the gel requires cooling to overcome the exothermic reaction especially when a powerin! source of light is used for final curing. Using heat alone, gelation occurs readily enough at appropriate temperatures but since the gel, when formed, has poor heat conductivity, fracturing may occur in the last stage. Through the use of heat and catalyst, the reaction may become very violent unless the heating is carefully controlled.

Various combinations of these three factors may be used to bring about hardening of the mass. Mild heating of the reactive resin and reactive material containing the CH2=C group with or without inhibitors brings about a very gradual increase in viscosity which'may be controlled quite easily and readily. When the solution has taken on an appropriate consistency, then accelerators may be introduced and heating conducted at a very much lower temperature. Mild heating may first be used and the mass then exposed to light.

a hard massive structure,

a relatively long bodyinl. the induction time may be decreased markedly.

WhileI have specifically described the reaction of mixtures of a reactive resin and a reactive material containing the CH2=C group in the liquid state I am not precluded from reacting the reactive material in the vapor state with the resin. Compositions containing a reactive resin and a reactive material containing the CH2=C group are originally liquid compositions and by proper treatment at relatively low temperature they can be converted into hard masses. The wide divergence of the properties of such compositions enables them to be used in a variety of different ways. In the liquid form they may be used as an adhesive, impregnating agent or as a surface coat ing. In that the hardening does not depend upon evaporation. the liquid may be applied to the surfaces desired with the reactive resin mixed with the reactive material containing the CHr==C group which acts as the solvent and combining in situ to form a homogeneous adhesive. Such an adhesive can be used for bringing diverse substances together, wood, metal, glass, rubber, or other resinous compositions such as phenolic or urea condensation products. As a surface composition in the liquid form, softening agents, cellulose ethers or esters could be added as well as natural or artificial resins, and the hardenin brought about through catalysts such as cobalt salts. oxygen liberating substances or hardening could be accomplished with light. Since these compositions dry from the bottom rather than from the top, the latter frequently remains tacky for a relatively lengthy period. In order to overcome this, drying oil fatty acids, e. g., linseed oil fatty acids are added to the esteriflcation mixture in making the original reactive resin and this will cause the top surface to dry quickly upon subsequent polymerization with a reactive material containing the CH2=C group. In this way a coating composition is obtained which dries both from top and bottom.

The liquid resinous composition, moreover, may be cast or molded and after hardening may be isolated as a finished product, or could be cut, turned and polished into the desired finished product. Provided the surface of the mold is highly polished, the resinous substance would acquire a clear, smooth finish from the mold. The

compositions so obtained being insoluble are not easily attacked by solvents and being infusible may be worked with ordinary wood working or metal tools. The artificial mass can be cut, turned on a lathe, polished and sanded without superficial softening and streaking.

Obviously natural resins or other synthetic resins may be admixed with the resins tion in order to obtain products suitable for particular purposes. Examples of these are shellac, cellulose esters and ethers, urea resins, phenolic resins, alkyd resins, ester gum, etc. The resins of my invention may also be mixed with rubber or synthetic rubber-like products if desired.

In that many of these resins are originally transparent and free of color, they may be colored with suitable dyes to a wide variety of transparent soft pastel shades. An example of a suitable dye is Sudan IV. Darker shades may be obtained, if desired. e. g., with nigrosine.

It may be desirable in some instances to form a copolymer of one or more substances containing the group CH2=C and at least one polymerizable unsaturated alkyd resin and, after molding or casting this into any desired shape, to apply a resin resulting from of this invencoating of a harder copolymer to the outside, thus obtaining the same effect as is obtained in the metallurgical fields by case hardening. Similarly, inserts may be filled with a hard resin in order to act as bearing surfaces or for some other purpose. Such coatings or inserts adhere tenaciously and appear to become integral with the original piece. In order to secure the best results in manufacturing such products. it is desirable to first abrade the surface of the article before the application of the harder film. During the cur.- ing operation, the abrasion marks disappear. This treatment is also of considerable importance since it may also be used to refinish articles which might have been marred in use.

- Many of the advantageous properties of the the polymerization of mixtures containing reactive materials containing the CH=C group and reactive resins are apparent from the foregoing disclosure. Several important advantages are now to be set forth.

In molding and casting operations curing takes place either in the presence or absence of air very rapidly. This is of great importance in curing large blocks. Other alkyd resins require a very much longer time to cure in large blocks. 1. e., many months, whereas the composition of a reactive resin and reactive materials containing the CH=C group require only a few days, at the most.

Another important advantage is the fact that the reactive material containing the CH2=C group which acts asthe solvent combines with the resin leaving no residual solvent and giving no problems as to solvent removal. I

One of the outstanding advantages of these resins is quick curing time which renders them available for injection molding, blow molding, and extrusion molding.

Castings which are polymers of such substances as methyl methacrylate, for example, frequently contain bubbles which are formed in the lower part of the casting. Inasmuch as the present invention is directed to systems wherein the polymerization proceeds from the bottom to the top, no bubbles are trapped in the casting.

Similar advantages are present in coating operations such as the lack of shrinkage of the film due to loss of solvent because of the combination between the reactive resin and the reactive material containing the CH2=C group which acts as the solvent. Furthermore, the composition dries from the bottom, there are no bubbles from the solvent and there is no water driven off. A clear bubble-free, impervious coating is, therefore, more readily obtainable with the combinations of a reactive resin and reactive material containing the CH=C group than with other coating compositions. Since there is no solvent to be removed and since air is not needed to dry the compositions, relatively thick layers may be applied in one operation.

This application is a continuation-in-part of my copending applications Serial Nos. 248,538, filed December 30, 1938, now abandoned; 349,240. filed August 1, 1940, now abandoned; 487,034, filed May 14, 1943; and 495,212, flied July 1'1, 1943, now Patent No. 2,409,633, October 22, 1946.

Obviously many other reactants and modifications may be used in the processes outlined in this specification without departing from the spirit and scope of the invention as defined in the claims.

I claim:

l. A polymerlzable composition comprising (1) a. polymerizable unsaturated alkyd resin obtained by reaction of ingredients including a. polyhydric alcohol, alpha, beta unsaturated polycarboxylic acid and a monocarboxylic acid, (2) another different substance which is a polymerizable monomeric polyallyl ester of a polybasic acid compatible with said resin, and (3) a catalyst for accelerating the copolymerization of 1) and (2),

2. A composition comprising the product of polymerization of a polymerizable mixture including 1) a polymerizable unsaturated alkyd resin obtained by reaction of ingredients comprising a polyhydric alcohol, an alpha unsaturated alpha beta. polycarboxylic acid and a monocarboxylic acid and (2) another different substance which is a polymerizable, monomeric polyester compatible with the resin of .l.) and obtained by esteriflcation of a polycarboxylic acid with allyl alcohol.

3. A composition comprising the product of polymerization of a polymerizable mixture including 1) a polymerizable unsaturated alkyd resin obtained by reaction of ingredients comprising a polyhydric alcohol, an alpha unsaturated alpha beta polycarboxylic acid and a monocarboxylic acid and (2) a polyallyl ester of an alpha unsaturated alpha beta polycarboxylic acid, said ester being compatible with the resin of 1).

4. The method of producing new synthetic compositions which comprises polymerizing a polymerizable composition comprising (1) a polymerizable unsaturated alkyd resin obtained by reaction of ingredients comprising a polyhydric alcohol, an alpha unsaturated alpha beta polycarboxylic acid and a monocarboxylic acid, (2) another difierent substance which is apolymeriza'ble, monomeric polyester compatible with the resin of (l) and obtained by esteriflcation of a polycarboxylic acid with allyl alcohol, and (3) a catalyst for accelerating the copolymerization of the materials of (1) and (2).

5. A synthetic, polymerized composition consisting of an interpolymer resulting from the polymeriz'ation of a mixture of copolymerizable materials consisting of a polymerizable monohydric alcohol polyester of an alpha unsaturated alpha beta polycarboxylic acid and a polymerizable es- 'terification product of a polyhydric alcohol, an

alpha unsaturated alpha beta polycarboxylic acid and a monocarboxylic acid.

6. A synthetic, resinous composition consisting of the product of polymerization of a mixture of copolymerizable materials consisting of (1) an unsaturated monohydric alcohol polyester of an alpha unsaturated alpha beta polycarboxylic acid and (2) a polymerizable esterification product of a dihydric alcohol, an alpha unsaturated alpha beta dlcarboxylic acid and a monocarboxylic acid.

7. As a new product, a synthetic resin consisting of an interpolymer of diallyl maleate and a polymerizable esterification product or a polyhydric alcohol, an alpha unsaturated alpha beta polycarboxylic acid and a monocarboxylic acid.

8. A polymerizable composition comprising 1) a polymerizable unsaturated alkyd resin obtained by the reaction of ingredients comprising a monocarboxylic acid, a dihydric alcohol and an alpha, beta. unsaturated dicarboxylic acid, (2) diallyl maleate and (3) a catalyst Ior accelerating the copolymerization of the materials of (1) and 2).

9. A polymerizable composition comprising (1) a polymerizable unsaturated alkyd resin obtained by the reaction of ingredients comprising a menocarboxylic acid, a polyhydric alcohol, an alpha, beta unsaturated dicarboxylic acid and (2) another diiferent substance which is a polymerizable, monomeric polyallyl ester of a polybasic acid compatible with said resin of (1) 10. A polymerizable composition comprising 1) a polymerizable unsaturated alkyd resin obtained by the reaction of ingredients comprising a monocarboxylic acid, a glycol and an alpha, beta unsaturated dicarboxylic acid and (2) another difierent substance which is a polymerizable, monomeric polyester compatible with the resin of 1) and obtained by esterification of an alpha, beta unsaturated dicarboxylic acid with allyi alcohol.

11. A polymerizable composition comprising (1) a polymerizable unsaturated alkyd resin obtained by the reaction of ingredients comprising a monocarboxylic acid, a dihydric alcohol and an alpha, beta unsaturated dicarboxylic acid and (2) diallyl phthalate.

12. A polymerizable composition comprising 1) a polymerizable unsaturated alkyd resin ob tained by the reaction of ingredients comprising a monocarboxylic acid, a dih'ydric alcohol and an alpha, beta unsaturated dicarboxylic acid and (2) another diiTerent substance which is a polymerizable, monomeric polyester of a dicarboxylic acid and ally] alcohol, said substance being compatible with said resin of 1) 13. A method of producing new synthetic compositions which comprises inter-polymerizing a polymerizable composition including (1) a polymerizable unsaturated alkyd resin obtained by the reaction of ingredients comprising a polyhydric alcohol, an' alpha unsaturated alpha, beta polycarboxylic acid and a monocarboxylic acid,

(2) another diiferent substance which is a polymerizable monomeric polyallyl ester of a polybasic acid compatible with the resin of (1), and ('3) a catalyst for acceleratin the copolymerization of the materials of (1) and (2).

14. A polymerizable composition comprising 1) a polymerizable unsaturated alkyd resin obtained by the reaction of ingredients comprising a glycol, an alpha, beta unsaturated polycarboxylic acid and linseed oil acids and (2) another difl'erent substance which is a compatible polymerizable monomeric polyallyl ester of a polycarboxylic acid.

EDWARD L. KROPA.

REFERENCES CITED The following references are of record in the file of this patent:

UNITED STATES PATENTS Number Name Date 1,921,756 Klenle Aug. 8, 1933 2,005,414 Dykstra June 18, 1935 2,155,590 Garvey Apr. 25, 1939 2,195,362 Ellis Mar. 26. 1940 2,202,846 Garvey June 4, 1940 2,255,313 Ellis Sept. 9, 1941 Certificate of Correction June 22, 1948.

Patent No. 2,443,739.

EDWARD L. KROPA tified that errors appear in the printe It is hereby oer iring correction as follows:

column 4, line 35, for

numbered patent requ Column 3, line 28, for fumerate read jumarate; aldehydric read aldehydt'c; column 7, Example 9, in the table, first column, line 1 W of the heading thereto, for Thiethylene read Triethylene; column 9, line 7 5, Example 17, for 7.3 X 105 read 7.8 X 10 column 13, line 7, Example 28, for OH read CH O column 19, line 13, for the Word filter read filler; line 65, for

C=(l1-( )=C) read o=( :-o=o) Letters Patent should be read with these corrections therein that and that the said form to the record of the case 1n the Patent Ofiice.

the same may con Signed and sealed this 21st day of June, A. D. 1949.

d specification of the above THOMAS F. MURPHY,

Assistant Commissioner of Patents. 

